1. APPLICATION FOR 10th CYCLE OF QCI D.L. SHAH QUALITY AWARDS
J.K. Fenner (India) Limited
3, Madurai-Melakkal Road
Kochadai, Madurai –
Tamil Nadu, India

2. J.K.Fenner (India) Limited
Madurai

3. Contact details Contact details of Chief Executive
Mr. PGS Dinesh Davidson
PLANT HEAD.
3 Madurai Melakkal Road
Kochadai, Madurai
Phone
Mobile :
Contact details of Project Leader
Mr. G Rajasekar
Head (Engineering)
3 Madurai Melakkal Road
Kochadai, Madurai
Phone
Mobile :

4. “CASE STUDY TO REDUCE STEAM COST” J.K.Fenner (India) LimitedBy
J.K.Fenner (India) Limited
Madurai

5. TEAM DETAILS Mr. PGS Dinesh Team Facilitator Mr. G Rajasekar
Engineering Dept.
Leader
Mr. V Murugan
Materials Dept.
Member
Mr. G Karthik Rajkumar
Engineering Dept.
Member
Mr. J Sivakumar
HR Dept.
Member

6. Methodology 1 12 2 11 3 10 4 9 5 8 7 6 Trail Implemen -tation
Identification of
Problem
Select the
Understand
the
Analysis
Identify
possible
Causes
Root cause
Data
Developing
Solutions
Foreseeing
Probable
Resistance
Regular
Implementa
-tion
Follow up/
Review 1 2 3 4 5 12 11 10 9 8 7 6

7. EXPECTED COMPLETION DATE:31.01.2014
GANTT CHART
PROJECT START ON :
EXPECTED COMPLETION DATE:
S.No.
Phase
Schedule
July
Aug
Sep
Oct
Nov
Dec
Jan
Feb 1
Identification of work related problems
PLAN
ACTUAL 2
Selection of Problem 3
Define the Problem 4
Analyze the Problem 5
Identification of causes 6
Finding out the root causes 7
Data analysis 8
Developing solution 9
Foreseeing probable of resistance 10
Trail implementation & Check performance 11
Regular Implementation 12
Follow –up / review
Note :
PLAN
COMPLETED ON TIME
DELAYED COMPLETE

8. IDENTIFICATION OF WORK RELATED PROBLEM
STEP - 1 1 2 4 5 6 7 8 9 10 11 3 12
IDENTIFICATION OF WORK RELATED PROBLEM

9. SELECTION OF PROBLEM
Members ranked problems based on the following categories
1. Productivity
2. Quality
3. Cost
4. Delivery
5. Safety
6.Morale
Score were given (1-6) for all the categories by the Team Members&
Final score card was generated.

10. SELECTION OF PROBLEM CATEGORY
TEAM MEMBERS
Total
Rank
PGS
GRS
JSK VM
KRK P 4 5 23
III Rank Q 6 3 2 20
II Rank C 29
I Rank D 14 IV S V M 1 VI
Team members decide to select a COST related problem

11. STEP - 1 IDENTIFICATION OF WORK RELATED PROBLEM
S.No
PROBLEM DESCRIPTION
CATEGORY
STATUS
A-Type
B-Type
C-Type
Reduction of power cost 1
Cooling water stirred by compressed air
Completed 2
High start up current for heavy machines 3
Continuous running of dust collector motor while not in operation 4
Continuous running of vacuum pump 5
Conventional lighting system
Under Progress 6
High captive power usage
Reduction of Fuel cost 7
Steam lines not insulated 8
No heat recovery from steam condensate 9
High steam cost
Under progress 10
Vulcanizer volume not used effectively

12. Type A -- Minimum involvement of other Department in Solving
STEP - 1
IDENTIFICATION OF WORK RELATED PROBLEM
S.No
PROBLEM DESCRIPTION
CTEGORY
STATUS
A-Type
B-Type
C-Type
Reduction of SSRM cost 11
High breakdown
On-going 12
No spares standardization
Others 13
More oil leakage
Regular 14
More air leakage 15
More minor incident 16
High water purchase cost
Type A Minimum involvement of other Department in Solving
them. Can be solved by the team itself.
Type B Involvement of other Department is a necessity.
Type C Problems can be solved with Management assistance

13. We did Data Stratification for these 16 Problems (A,B &C)
STEP - 1
IDENTIFICATION OF WORK RELATED PROBLEM
We did Data Stratification for these 16 Problems (A,B &C)
PROBLEM IDENTIFICATION
Yes
Management
Approval
Required ?
Required other
department Help No
(Minimum)
A TYPE - 5
C TYPE - 7
B TYPE - 4

14. STATUS OF “ C” TYPE PROBLEMS
STEP - 1
IDENTIFICATION OF WORK RELATED PROBLEM
STATUS OF “ C” TYPE PROBLEMS

15. STEP - 2 1 2 4 5 6 7 8 9 10 11 3 12
SELECTION OF PROBLEM

16. STEP - 2
SELECTION OF PROBLEM
Problem Description
TEAM MEMBERS
Total
Rank
PGS
GRS
JSK VM
KRK
High consumption of
lighting power 1 2 8
III Rank
High exhaust of Flash steam 3 4 13
II Rank
High steam cost 18
I Rank
High Captive power usage 11 IV
Team members have identified High steam cost as the Highest ranking Problem

17. PROBLEM DEFINITION
Currently, we are running the boiler with Furnace oil as a fuel
The cost of furnace oil is un-predictable
The impact of high fuel expenses incurs into a high process cost which leads to increase in product cost

18. STEP - 3 1 2 4 5 6 7 8 9 10 11 3 12
DEFINE THE PROBLEM

19. THEME : To reduce the steam cost
PROBLEM DEFINITION
THEME : To reduce the steam cost

20. UNDERSTANDING THE PROBLEM
Better
Better

21. UNDERSTANDING THE PROBLEM
Continuous increase in Furnace oil price
Policy change by Govt. in petroleum products
Stock out of fossil fuel for boilers
SO2 emission in boiler stack

22. TARGET To reduce steam cost 18% reduction Fuel Cost Rs/kg of steam
Target Date –

23. STEP - 4 1 2 4 5 6 7 8 9 10 11 3 12
ANALYSE THE PROBLEM

24. Average Steam cost vs Fuel cost trend
Better
Inference : Fuel cost is increasing year on year

25. IDENTIFCIATION OF CAUSES
STEP - 5 1 2 4 5 6 7 8 9 10 11 3 12
IDENTIFCIATION OF CAUSES

26. BRAIN STORMING Brain storming points Low efficient boiler
Steam leakages in valves
Existing fuel cost is high
Improper insulation of delivery pipes
High fuel consumption during start up
Furnace oil contamination
Availability of Furnace oil
Government policy
No flexibility in fuel type
Steam leakages in pipelines
Pre-heating of vulcanizers
Fluctuating steam demand
Inefficient usage of steam

27. CAUSE VERIFICATION Sl. No Brain Storming Points Relevant or Not 1
Low efficient boiler
Not Relevant 2
Steam leakages in valves 3
Existing fuel cost is high
Relevant 4
Improper insulation of delivery pipes 5
High fuel consumption during start up 6
Furnace oil contamination

28. CAUSE VERIFICATION Sl. No Brain Storming Points Relevant or Not 7
Availability of Furnace oil
Not Relevant 8
Government policy 9
No flexibility in fuel type
Relevant 10
Steam leakages in pipelines 11
Pre-heating of vulcanizers 12
Fluctuating steam demand 13
Inefficient usage of steam

29. FINDING OUT THE ROOT CAUSES
STEP - 6 1 2 4 5 6 7 8 9 10 11 3 12
FINDING OUT THE ROOT CAUSES

30. Furnace oil used as a Fuel Fluctuation in crude oil price
WHY WHY ANALYSIS
Steam cost is high
( Why)
Furnace oil used as a Fuel
( Why)
Fluctuation in crude oil price

31. STEP - 7 1 2 4 5 6 7 8 9 10 11 3 12
DATA ANALYSIS

32. Furnace oil Rate trend
Better
Inference : Furnace oil rate is increasing year on year

33. STEP - 8 1 2 4 5 6 7 8 9 10 11 3 12
DEVELOPING SOLUTION

34. DEVELOPMENT OF SOLUTION
COUNTER MEASURE
To provide alternate fuel
Type of Alternate fuel
Feasibility
Remarks
DIESEL No
High Cost
GAS
Not feasible in Madurai
BIOMASS
Yes
Abundant availability

35. DEVELOPMENT OF SOLUTION
Biomass energy is derived from plants and agro waste
Biomass energy is getting widespread popularity
Juliflora

36. DEVELOPMENT OF SOLUTION
Advantages of Biomass
It is one of the most inexpensive fuel for producing heat
It is an inexhaustible natural resource
Availability of Juliflora ( Type of shrub) is in Abundance in South India
Biomass energy is capable of replacing fossil fuels

37. ACTION PLAN FOR SOLUTION
Biomass gasification process
Conversion of solid fuels into combustible gas mixture called producer gas (CO + H2 +CH4)
It involves partial combustion of biomass
Four distinct process in the Gasifier viz.
Drying
Pyrolysis
Combustion
Reduction

38. ACTION PLAN FOR SOLUTION
Feed
Cone
Skip Charger
Feed
Shell
Hopper
HAG
Reactor
Drying
Pyrolysis
Combustion
Reduction
Boiler
Rotary
Dryer
Silo Bin
Blower
Wet
Biomass
FURNACE OIL
Ash
Collection

39. ACTION PLAN FOR SOLUTION
Risk Analysis
Availability of raw material
Juliflora is being available in 25 Lakh Acres of land in and around South Tamil Nadu
Output per day is 2000 Tons
Our per day requirement is 40 Tons (2% of production)
Space availability
Space required is sqft
Created space for this project by layout modification

40. ACTION PLAN FOR SOLUTION
Analysis
Visited equipment supplier sites to understand the technical capabilities
Payback worked for this project
Investment for this project – Rs. 220 Lacs
Government subsidy – Rs.30 Lacs / approx
80% accelerated depreciation benefit – Rs.48 Lacs
Net investment on gasifier – Rs.142 Lacs
Advance Payment through performance bank guarantee
BOT (Built , Operate and Transfer) contract was made with the supplier

41. FORSEEING PROBABLE RESISTANCE
STEP - 9 1 2 4 5 6 7 8 9 10 11 3 12
FORSEEING PROBABLE RESISTANCE

42. FORSEEING PROBABLE RESISTANCE
Solid waste disposal
Bio char generation is 5-6% (2.5Tons / day)
It can be used as an excellent fertilizer due to higher carbon content (72%)
This can be given to near by farmers, which may be a part of “our CSR activities”
Can be disposed as a “landfill”
Can be used as a burning fuel for the cement industry
Statutory / Environmental aspects
No need for IBR certification for this alternate fuel system
Emission level is well within the CPCB (Central pollution control board) norm
No Sulphur content in the biomass and hence termed as GREEN ENERGY
Being a green energy, attractive subsidy also available from government (MNRE)
Technological aspects
No alteration in the boiler
Switch over / back up option with furnace oil
Got the consensus with the boiler manufacturer

43. TRAIL IMPLEMENTATION & CHECK PERFORMANCE
STEP - 10 1 2 4 5 6 7 8 9 10 11 3 12
TRAIL IMPLEMENTATION & CHECK PERFORMANCE

44. TRIAL IMPLEMENTATION & CHECK PERFORMANCE
Steam Cost Trend
Better

45. TRIAL IMPLEMENTATION & CHECK PERFORMANCE
Steam Cost Trend
Better

46. REGULAR IMPLEMENTATION
STEP - 11 1 2 4 5 6 7 8 9 10 11 3 12
REGULAR IMPLEMENTATION

47. REGULAR IMPLEMENTATION & CHECK PERFORMANCE
Steam Cost Trend
BEFORE
TRIAL
AFTER
Better 47 47

49. STEP - 12 1 2 4 5 6 7 8 9 10 11 3 12
FOLLOW - UP / REVIEW

50. STEP - 12 Actions for Follow up & Review: Standardization :
1.Bio Gasifier efficiency increased by decreasing moisture content in wood by providing wood storage shed. Target Date Completed
2. Nozzle modification for better air suction – Target date Completed
3.Conveyor to be provided for wood feeding – Revised target date
Standardization :
1.PM check list for Bio Gasifier implemented

51. AFTER 85% Before 40% INTANGIBLE BENEFITS AFTER BEFORE RADAR CHART20 40 60 80
100
AFTER
BEFORE
TEAM WORK
PROBLEM
SOLVING ABILITY
CREATIVITY
COMMUNICATION
SKILLS
INVOLVEMENT
QC KNOWLEDGE
TIME
MANAGEMENT
MORALE
INITIATIVE
UNDERSTAND CUSTOMER NEEDS
Before
40%
AFTER 85%

52. STEP - 12 TANGIBLE BENEFITS C - Cost E-Environmental
Steam cost reduced from Rs 3.05 per kg to Rs 2.40 per kg
E-Environmental
Boiler stack- SO2 reduced from 9.81mg/m3 to 4.92 mg/m3 and NOX reduced from 20.21mg/m3 to 11.57mg/m3

53. STACK MONITORING OF BOILER
Pollution Norms-80 mg/m3
FURNACE OIL
TRIAL
BIOMASS
Better

54. GANTT CHART PROJECT END ON :31.01.2014 PROJECT START ON :01.07.2013
S.No.
Phase
Schedule
July
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar 1
Identification of work related problems
PLAN
ACTUAL 2
Selection of Problem 3
Define the Problem 4
Analyze the Problem 5
Identification of causes 6
Finding out the root causes 7
Data analysis 8
Developing solution 9
Foreseeing probable of resistance 10
Trail implementation & Check performance 11
Regular Implementation 12
Follow –up / review
Note :
PLAN
COMPLETED ON TIME
DELAYED COMPLETE

55. HORIZONTAL DEPLOYEMENT
The same process will be implemented in our other plants

56. LESSONS LEARNT Risk taking ability Innovative ideas Think differently
Team Work is better than the individual’s Knowledge
Every problem has a solution
Quality of solution depends on the involvement
Self confidence of our team to solve bigger problems.
Each attempt is a good learning in Problem solving

57. FUTURE PLAN
We proudly say that we are the first in our country to install Bio Gasifier plant for steam generation
To implement this project in Madurai II plant
TARGET : BEFORE Oct ‘2015
Our journey towards becoming green and being a responsible corporate citizen Continues…….

58. Thank you